Prediction of the As-Cast Structure of Al-4.0 Wt Pct Cu Ingots

A two-stage simulation strategy is proposed to predict the as-cast structure. During the first stage, a 3-phase model is used to simulate the mold-filling process by considering the nucleation, the initial growth of globular equiaxed crystals and the transport of the crystals. The three considered phases are the melt, air and globular equiaxed crystals. In the second stage, a 5-phase mixed columnar-equiaxed solidification model is used to simulate the formation of the as-cast structure including the distinct columnar and equiaxed zones, columnar-to-equiaxed transition, grain size distribution, macrosegregation, etc. The five considered phases are the extradendritic melt, the solid dendrite, the interdendritic melt inside the equiaxed grains, the solid dendrite, and the interdendritic melt inside the columnar grains. The extra- and interdendritic melts are treated as separate phases. In order to validate the above strategy, laboratory ingots (Al-4.0 wt pct Cu) are poured and analyzed, and a good agreement with the numerical predictions is achieved. The origin of the equiaxed crystals by the “big-bang” theory is verified to play a key role in the formation of the as-cast structure, especially for the castings poured at a low pouring temperature. A single-stage approach that only uses the 5-phase mixed columnar-equiaxed solidification model and ignores the mold filling can predict satisfactory results for a casting poured at high temperature, but it delivers false results for the casting poured at low temperature.